Media Information
September 2009
Powertrain
Optimizing Power and Efficiency

New engine line-up cuts CO2 and fuel consumption by more than 12 percent

Choice of eight highly efficient engines, from 70 kW/95 hp to 132 kW/180 hp

ecoFLEX diesel with 109 g/km CO2; 100 hp gasoline with 129 g/km CO2

New compact six-speed automatic transmission
Rüsselsheim. The new Astra will launch with a complete line-up of eight engines ranging
from 70 kW/95 hp to 132 kW/180 hp, illustrating the brand’s philosophy of providing drivers
with affordable, real-life efficiency while still preserving a thrilling driving experience. The
new Astra has grown slightly to provide a roomier interior and, at the same time, it has
benefited from engineering enhancements that allow it to improve fuel efficiency and
performance.
The Astra’s line-up of powertrains with manual transmission provides impressive
performance and cuts fuel consumption and CO2 emissions overall by more than
12 percent compared with the current generation. The average fuel consumption of the
four diesel engines ranging from 70 kW/95 hp to 118 kW/160 hp, which are expected to
represent almost half of the new Astra cars sold in Europe at launch, is only 4.6 l/100 km.
The CDTI turbo diesel line-up includes 1.3, 1.7 and 2.0-liter units, each has common-rail
with multiple fuel injection equipped with particulate filters. Even the top-of-the-line 2.0
CDTI with 118 kW/160 hp only requires 4.9 l/100 km on average and emits no more than
129 g/km CO2.
A new diesel 1.3 CDTI ecoFLEX generation with CO2 emissions of only 109 g/km and an
average fuel consumption of just 4.2 l/100 km will be added to the range in spring 2010.
All performance, fuel consumption and CO2 emission figures are subject to change
Information concerning specifications and equipment applies to the models offered in Germany. There may be differences in other markets. All data on
fuel consumption are provisional. They refer to combined fuel consumption of the base model in the European test cycle and are subject to change.
Adam Opel GmbH
D-65423 Rüsselsheim
media.opel.com
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The gasoline range comprises naturally-aspirated and turbocharged 1.4 and 1.6-liter
engines, giving a power bandwidth from 74 kW/100 hp to 132 kW/180 hp. The average fuel
consumption of the four gasoline engine line-up is only 6.1 l/100 km.
The 74 kW/100 hp entry-level version in the gasoline line-up only consumes 5.5 l/100 km
and does not emit more than 129 g/km CO2. This makes it the most fuel-efficient gasoline
compact on the market. Continuing Opel’s strategy of downsizing, a new 103 kW/140hp
1.4 Turbo gasoline engine replaces the current 1.8 liter variant, improving fuel efficiency by
nearly 18 percent.
All transmissions are six-speed, with the exception of a five-speed manual gearbox for the
1.4 and1.6-liter naturally-aspirated and the 1.3 turbo diesel engines. A new, space-saving
automatic transmission is introduced in the gasoline range.
Four naturally aspirated or turbocharged high-efficient 1.4 and 1.6 gasoline engines
Four naturally-aspirated and turbocharged 1.4 and 1.6-liter engines compose a line-up of
74 kW/100 hp to 132 kW/180 hp.
All engines are transversely-mounted four-cylinder units with aluminum cylinder heads
carrying dual overhead camshafts that operate four valves per cylinder. Cylinder blocks are
in cast iron for strength and reduced noise resonance, with a hollow frame design for
minimized weight. A die cast, structural aluminum oil pan adds further stiffness and
provides further noise reduction.
Continuously variable valve timing is featured in all engines on both inlet and exhaust
sides, except the 1.6-liter turbo. The camshafts have hydraulically operated vane-type
phasers which vary the angle of each camshaft relative to the crankshaft by up to
60 degrees on the inlet side and 45 degrees on the exhaust side.
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Cam phasing allows the engine control module to adjust the timing of the opening and
closing of the valves according to varying conditions, such as engine speed and engine
load. The many benefits include a broader spread of torque, higher maximum power and
improved fuel consumption. Cam phasing is also an effective tool for controlling exhaust
emissions, managing valve overlap at optimum levels to eliminate the need for a separate
exhaust gas recirculation (EGR) system. The coolant thermostat and the oil pump are
electronically controlled to improve engine heat up.
The entry-level 1.4-liter, naturally-aspirated engine develops 74kW/100 hp at 6000 rpm,
with a specific power output of 52.8 kW/71.4 hp per liter. It focuses on excellent fuel
economy and returns 5.5 l//100 km over the combined cycle, the best figure for a gasoline
engine in the compact segment.
The camshafts are chain-driven for maintenance-free operation and automatic hydraulic
lash adjustment. Further refinements include the use of hollow camshafts, which reduce
weight and lower reciprocating mass, and a torsional vibration damper that improves
running refinement. The fuel injection system also features port deactivation under part
load for improved exhaust gas recirculation, giving lower emissions and improved fuel
consumption.
The 1.6-liter naturally-aspirated engine, develops 85 kW/115 hp at 6,000 rpm and has an
even higher specific power output (72.5 hp) per liter than its 1.4-liter, naturally-aspirated
cousin. Maximum torque of 155 Nm is generated at 4,000 rpm, with more than 90 percent
of this value available from 3,000 rpm. The combined cycle fuel consumption is
6.3 l/100 km.
A two-stage variable intake manifold is fitted to this engine. For increased torque at engine
speeds below 4,000 rpm, the fuel/air intake charge passes through 620 mm long inlet
tracts. Above 4,000 rpm, the engine management system transmits a signal to channel the
air along shorter 288 mm tracts, which has the effect of increasing top-end engine power.
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The engine’s cylinder barrels are laser-etched for an extremely smooth finish. This results
in minimal piston friction and wear characteristics, while also benefiting oil and fuel
consumption. Under-skirt piston oil cooling is a further addition.
The new, downsized 103 kW/140 hp 1.4-liter turbo engine that replaces a naturallyaspirated 1.8 engine of similar output is focused on strong performance with high elasticity,
enabled by 200 Nm of torque available between 1,850 and 4,900 rpm. Compared to the
140 hp/175 Nm 1.8 engine from the current range it replaces, it delivers 14 percent more
torque with an impressively low fuel consumption of 5.9 l/100km – an improvement of
nearly 18 percent. These power characteristics translate to a zero to 100 km/h acceleration
in 9.7 seconds, and a transition from 80 to 120 km/h in fifth gear swiftly accomplished in
13.3 seconds.
The water-cooled turbocharger, spinning at up to 240,000 rpm, is integrated into the
exhaust manifold close to the engine for a fast throttle response. Air-to-air inter-cooling
increases the intake charge density.
The adoption of a reinforced crankshaft, reinforced pistons and con-rods allows the use of
relatively high 9.5:1 compression ratio, despite higher stresses and loads. Under-skirt
piston oil cooling jets, an oil cooler and exhaust valves filled with sodium are further
features ensuring durability under higher internal temperatures.
The most powerful gasoline engine is the 1.6-liter turbocharged which exceeds 110 hp
per liter in delivering a maximum power of 132 kW/180 hp. Developed for customers
focusing on dynamic driving characteristics, it is the most powerful production engine in its
displacement class.
Great performance is matched by an impressively wide plateau of torque, with 230 Nm
available all the way from 2,200 rpm to 5,400 rpm. For quick and safe overtaking
maneuvers, an overboost function can briefly unleash even more torque, raising it to
266 Nm for up to five seconds.
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With this engine, the new Astra achieves zero to 100 km/h acceleration in 8.5 seconds,
and makes the 80 to 120 km/h transition in fifth gear in just 10.5 seconds.
Like the 1.6 naturally-aspirated engine, the cylinder barrels are laser-etched for minimal
piston friction. To withstand higher operating temperatures, the exhaust valves are filled
with sodium and under-skirt piston cooling with oil jets is used. A map-based thermostat
control raises the coolant temperature at low engine speeds or under light loads to help
reduce internal lubricant friction and improve fuel consumption.
Three diesel engines in four output variants require less than 5.0 liter/100 km
The CDTI turbo diesel line-up includes 1.3, 1.7 and 2.0-liter units - all common-rail with
multiple fuel injection and standard particulate filter – which range in power from
70 kW/95 hp to 118 kW/160 hp. All benefited from the latest developments and
refinements in engine management calibration, which allowed an impressive 14.5 percent
improvement in fuel efficiency across the range compared to the already frugal current
Astra diesel line-up. The four engines require less than 5.0 liter/100 km on average - with
CO2 emissions that do not exceed 129 g/km - even for the powerful 118 kW/160 hp
2.0 CDTI. A first ecoFLEX generation powered by the 70 kW/95 hp 1.3 CDTI engine with
CO2 emissions of only 109 g/km and average fuel consumption of only 4.2 l/100 km will be
added to the range in spring 2010.
All CDTI engines in the Astra are fitted with 16-valve, dual overhead camshafts, a weightsaving aluminum cylinder head, specially shaped intake ports for exceptional swirl and
burn characteristics, oil-jet-cooled pistons, a dual-mass flywheel and a maintenance-free
particulate filter. The main technical features include:
 Common Rail, Multiple Fuel Injection:
Operating at high pressures up to 1,800 bar (1,800 bar for the 1.7-liter; 1,600 bar
for the 1.3- and 2.0-liter engines), this sophisticated fuel delivery system ensures
extremely fine atomization in the combustion chamber and enables up to five
injection pulses per cycle to extract as much energy as possible from a given
amount of fuel. This results in exceptionally-low fuel consumption and exhaust
emissions, as well as reduced engine noise. Multiple injections help iron out the
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strong vibrations associated with compression ignition. For example, a preinjection during the warm-up period reduces cold-start ‘knock’ to a barely
perceptible level.
 Variable Geometry Turbocharger (VGT):
The pitch of the vanes on the turbine wheel is continuously varied according to
engine load and speed, giving an excellent throttle response, particularly during
pick up from low speeds.
 Improved Exhaust Gas Recirculation (EGR):
The electronically-controlled EGR system has an additional cooling function.
Electro-pneumatically operated bypass flaps controlled by the engine management
system ensure that the exhaust gas reaches a temperature suitable for combustion
on its way back into the cylinder. This contributes to increased power as well as
reduced emissions.
Acclaimed for its compact size, the 70 kW/95 hp, 1.3-liter CDTI in the new Astra ecoFLEX
offers outstanding fuel economy of just 4.2 l/100 km over the combined cycle and CO2
emissions of only 109 g/km. Strong torque of 190 Nm between 1,750 and 3,250 rpm belies
the small capacity of this engine.
The 1.7-liter CDTI comes in two states of tune, providing 81 kW/110 hp and 260 Nm, or
92 kW/125 hp and 280 Nm of torque. Combined cycle fuel consumption in both cases is
4.7 l/100 km.
The 2.0-liter CDTI which debuted in the Insignia packs 118 kW/160 hp with an
impressively strong torque of 350 Nm from just 1,750 rpm. With the overboost function,
380 Nm can be reached for up to 15 seconds, giving the driver extra power when needed.
The result is outstanding performance – with zero to 100 km/h achieved in 9.0 seconds –
together with combined cycle fuel consumption of just 4.9 l/100 km.
A choice of transmissions that includes a new 6-speed automatic
Six-speed manual gearboxes offering a wide spread of ratios and a long, fuel-saving top
gear are a standard fit across the range, with the exception of the 1.4/1.6-liter naturally-
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aspirated and the 1.3-liter turbo diesel engines which have five-speed gearboxes. Such
five-speed, two-shaft units are preferred due to their advantages in efficiency and mass
balance, optimizing fuel economy. All gearboxes feature triple cone synchronization in the
first and second gears for easy engagement.
An all-new, six-speed automatic transmission with an ActiveSelect function is available as
an option with all gasoline engines except the 1.4-liter naturally-aspirated unit which is
manual only.
The on-axis design allows more compact packaging, resulting in enhanced crumple zone
performance, increased interior space, and a lower hood line than with a conventional offaxis design. Instead of the transmission being folded around the end of a transverselymounted engine, the gear sets are now on the same axis as the engine crankshaft
centerline, which makes the entire powertrain unit much shorter fore-to-aft. Shifts are
accomplished by applying and disengaging clutches simultaneously, which provides
increased functionality and a more direct feel for the driver compared to freewheeling gear
change mechanisms.
On the road, a wide selection of shift patterns is adapted to the styles and habits of the
driver, anticipating when maximum acceleration or maximum efficiency is required. The
electronic control also adapts to the prevailing road conditions, reducing gear shifting when
climbing or descending and using engine braking assistance during down shifts.
ActiveSelect allows sequential driver gear selection via the shift lever. The driver also
benefits from neutral gear disengagement at idle, which reduces vibration and contributes
to improved fuel consumption.
Hydraulically-damped mountings for smoother operation
All powertrains are bolted in position via hydraulically-damped mountings that minimize
vibration through the body structure. Adaptor plates enable the same four fixing points to
be used for all applications, two on the front sub-frame and one on each longitudinal beam.
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The fuel supply system uses an electric pump and filter mounted in the 56-liter fuel tank,
which is located low under the rear seat for optimal weight distribution and crash impact
protection.
Contact:
Nathalie Van Impe
+ 49 6142 7 66166 (office)
+ 49 151 174 73959 (mobile)
nathalie.van.impe@de.opel.com
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